DE10342540A1 - Process for the production of metal-containing components and rolled profiling plant for profiling metal-containing components - Google Patents

Abstract

In the production of metal-containing components by deep drawing, the component geometry is limited due to the process. The method for producing metal-containing components and the roll forming system (17) for profiling metal-containing components, in particular vehicle support structures, in which a metal-containing starting material is fed to a roll forming system (17) and roll profiled into a rolled section (14) and during which during roll forming ( 4, 6) forming takes place (5), ensures that by means of the forming (5) of the rolled section cross section is changed. A cross-sectional change is particularly important for structural and safety components and for column structures, longitudinal and transverse profiles, such. B. side impact beams, bumpers, pillar reinforcements, longitudinal and cross member, floor assembly and roof frame.

Description

The The invention relates to a process for the production of metal-containing Components according to the preamble of claim 1 and a roll forming for profiling of metal-containing components according to the preamble of claim 8.

Well known is the production of components with elongated profiles by means of conventional deep drawing. Here, a separate suitable thermoforming tool is necessary for each component variant. Due to the process, there are forming limits during deep drawing, such as limited drawing depth, complex component geometries, realization of undercuts. The processing of higher-strength steels, preferably having a tensile strength of up to 1500 N / mm ² , proves to be troubling during deep drawing of metallic components, in particular support structures, since these have increased yield strengths and reduced elongations at break, which on the one hand requires increased forming forces and, on the other hand, the deformed metallic components spring back more elastic.

From the publication DE 101 20 063 C2 is a method for the production of metallic components for motor vehicles by roll forming known, in which components of strip-shaped starting material with continuously the same profile cross section, in particular a U-shaped profile cross-section, are bent during roll forming. These components prove to be unsuitable for complex vehicle support structures. This document was used to form the generic terms.

A method for partial roll forming with an upstream or integrated cutting device for cutting, in particular punching, of elongated starting materials and generating a cross-sectional change of the component hollow profile by trimming, is from the document DE 197 49 902 A1 known. In this case, the hollow component profile on an interrupted component surface with a reduced torsional and bending stiffness. Due to the reduced rigidity of the component produced by this separation method, this method proves to be unsuitable for structural and safety components. Furthermore, the processing by punching of high-strength steels leads to increased wear of the punching tool, which leads to increased tooling costs and set-up times and makes the machining process uneconomical. The processing of the rolled section by means of cutting, in particular laser cutting, proves to be unfavorable for safety components, since unavoidable microstructural changes in the highly stressed edge region of the profile occur during laser cutting, which have a negative effect on the component strength under oscillating stress.

Of the present invention is based on this prior art The task is based on a method for creating dimensionally stable Specify components and a device for profiling especially to provide stable components.

These Task is with the features of claim 1 in relation to the inventive method and claim 8 with respect to the rolling profiling plant to be created solved.

The inventive solution given by a method for producing metal-containing components, in particular of vehicle support structures, in which a metal-containing Feedstock fed to a roll forming and to a roll profile is roll profiled, wherein during the Roll forming a forming takes place such that by means of Forming the rolled section is changed.

One An essential advantage of the process according to the invention is the production of components with over the length, in height and / or changed in width Roll profile cross section by means of continuous or discontinuous Roll forming and integrated forming. In the method according to the invention becomes a cross section change introduced by forming, so that a reduction of Torisons- and flexural rigidity a component made by means of cutting avoided. This allows this inventive method the production of components with very good structural properties in the highly stressed edge area of the component cross section, which is positive on the component strength under oscillating stress impact.

Another significant advantage of the method according to the invention is the production of structural and safety components from high and higher strength steels, preferably with a tensile strength up to 1700 N / mm ² , which meet the safety requirements in motor vehicle construction. As a rule, the structural and safety components are thin-walled pillar structures made of sheet steel, longitudinal and transverse profiles, such as side impact beams, bumpers, pillar reinforcements, longitudinal and transverse beams, floor pan and roof frames. These are characterized by a high dimensional stability, lower tolerances, the better integration by joining, in particular by laser welding, such as welding a floor group to a side member.

Especially Body structures, such as support structures, often need the place of installation, in particular for adaptation to the weld joint, be adapted in cross section so that they do not have a consistent over their longitudinal course Have cross-section. By means of the method according to the invention carrier structures manufactured such that the rolled section cross section is changed.

One significant advantage of the method according to the invention in comparison to the components produced in particular by means of conventional deep drawing from elongated profiles, is essentially the better dimensional accuracy while the production of elongated components.

In a particularly advantageous embodiment of the method according to the invention The process steps are Roll Forming, Forming and Roll Forming go through one after the other.

The Roll forming is the traditional manufacturing process for cold profiling, such as Swing or swivel bending, due Clearly superior to low production times. Both by the high output rate per time as well as the low tooling costs Compared to deep drawing, the production times are significantly reduced. That is why there is one in the range of medium to large lot sizes high efficiency of the process.

Thereby, that the metal-containing starting material is preferably first addressed and then marked before it then the Walzprofiliervorgang supplied and then is deformed by a forming process and then roll profiled again It is achieved that by means of rolling profiling with the integrated Forming a component with over its longitudinal course changed roll profile cross section can be produced, which is adapted exactly to the later intended use is. In this advantageous embodiment of the invention takes place the production of the rolled section and the production of the modified one Roll section cross-section in one work passage saving time without intermediate storage and the associated logistics costs.

One a significant advantage of the method according to the invention is that the successive process steps in a compact device carried out can be which proves to be particularly economical.

In an advantageous embodiment of the invention is provided that the roll forming with the forming device in the discontinuous Operation is controlled.

One Advantage of this embodiment is the attachment of complex Walzprofilquerschnittsvariationen on designated component areas with different component lengths. The Walzprofilieranlage is controlled so that the changing Component area is transformed in the forming device. To reshape carry out to be able to If the roll forming system is preferably stopped for one to two seconds, The rolled section will be reshaped and the rest will follow Roll forming takes place. The integration proves to be advantageous the forming in the Walzprofilierprozess, the Walzprofiliervorgang conventionally carried out or is executed as a flexible Rollprofiliervorgang can.

In another advantageous embodiment of the method according to the invention the roll profile changes the cross section cold formed.

A Such an embodiment of the method according to the invention has the significant advantage across from a conventional one Hot forming, in particular with respect to a tempering followed by roll forming, that, on the one hand, lower legal costs caused and on the other hand increased plastic residual strain due to a more ductile material condition. Additional wise the method according to the Invention compared with manufactured components the means of a conventional Hot-formed components, a higher dimensional accuracy, resulting in a Calibration to be performed in the cold state the components omitted. For example, must carrier or A, B, C or D pillar structures in the automotive industry with high quality and thus high dimensional accuracy in large quantities getting produced. By means of the method according to the invention is a high dimensional stability and ensures better buildability in the shell.

In a further advantageous embodiment of the method according to the invention is beaded during forming and / or on train and / or pressure, in particular deep-drawn and / or stretch-drawn, formed.

It is advantageous that with the integrated tensile and / or pressure forming, in particular by deep drawing, over a constant profile cross-section complex cross-sectional changes in desired component areas can be introduced, the wall thicknesses of the components remain virtually unchanged. The method according to the invention proves to be particularly advantageous in that after the first roll profiling and prior to further roll forming metal-containing starting materials, in particular high-strength steels, deep-draw without negative adverse effects on the mechanical properties of the component to be formed. Thus, the inventive method ensures a transformation to complex, particularly dimensionally stable components.

alternative or additively to this embodiment can by means of ironing components with changed Final dimensions are produced, which have a constant profile cross-section complex cross-sectional changes in desired Component areas and additionally reduced wall thicknesses exhibit. The combination of ironing with deep drawing allowed large-scale unbalanced Produce components.

alternative or additively thereto, by means of preferably in the roll forming process integrated beading, made of components that have both variable cross-sectional changes as well as in desired component areas have geometrically shaped stiffeners (beads).

A Such an embodiment of the method according to the invention has the further Advantage that the means of deep drawing and / or ironing and / or Beading machined component areas not in a single step, but can be gradually transformed to a form favorable structural state over the Set cross-section of the component.

In a further advantageous embodiment of the method according to the invention the roll profile is locally and thus spatially limited by means of a forming device, i.e. no over the whole length of the Component, reshaped.

Of the Advantage of this embodiment of the method according to the invention is because, for example, by the localized forming elongated Components with a reduced sheet thickness in zones of lower load and with an optionally slightly increased sheet thickness in zones higher Load can be produced.

By the inventive method Is it possible dependent on the requirements of the installation point for desired components a functional cross section provided. The local deformation of the rolled section takes place exactly in the desired Component area instead, so that 'customized Components manufactured can be.

Of the Advantage of the method according to the invention also lies in the fact that by means of local localized forming Components such as side member, cross member and Column structures, the similar to each other are, but different lengths have, are easier to produce.

In a preferred embodiment of the method according to the invention are higher strength as starting material steels and / or deep drawing steels and / or Ti alloys and / or Ni alloys and / or metal-containing composite materials used.

One Advantage of the method according to the invention is the use of high and / or higher strength steels as Starting material, the roll profiled, then transformed into a Rolled profile with a variable cross-section and then on can be profiled roll. In addition to weight reduction, these materials have the advantage that requires less installation space On the other hand, the increasing security requirements in the Automotive engineering in the field of structural and safety components Fulfills can be.

One An essential advantage of the process according to the invention is the production of support structures made of materials that can not be formed by conventional deep-drawing are. In particular, higher strength steels (see lightweight steels), preferably from the group of multiphase steels, such as dual-phase steels (DP steels), complex-phase steels (CP steels), martensite steels (MS-W steels) or Retained austenitic steels (transformation induced plasticity TRIP steels), the conventional by conventional deep drawing can not be reshaped, are suitable Great for Roll forming with integrated deep drawing. These steels show especially cheap Strengthening properties in terms of formability strength ratio. The Increasing the strength of these steels is achieved by hard phases in a ductile material matrix be introduced. Characteristic of these steels is the addition to the solidification superimposed "bake-hardening" potential that with the increasing transformation becomes larger. The very high availability of these steels with high initial strength is particularly advantageous for the crash behavior. Thus, the inventive method allows an increase in strength in desired component areas also by the choice of a suitable material without, for example, a costly heat treatment needed becomes.

alternative or additively to it According to the invention, deep-drawing steels in structural and safety components are used because they have a low carbon content also have a fine-grained, preferably texture poor microstructure and a Yield point without flow range exhibit.

Ti alloys or Ni alloys are suitable to deform only moderately with conventional forming processes. Nevertheless, these can be processed by forming technology by means of the method according to the invention. This process can also transform Mg or Al alloys.

Cross member, manufactured made of Mg alloys, are opposite appropriate carriers made of steel, despite lower modulus of elasticity and strength characteristics of the Mg alloys, lighter.

It it is conceivable to use metal-containing composite materials for structural and safety components. The advantage of these materials is that they are "tailor made" for the components can be used so reinforcements only in the desired Component areas can be introduced.

Advantageous in the method according to the invention the use is higher strength Steels. Typically, however, these are more brittle, their ductility (ductility) decreases in this scale, how their strength increases. The inventive method allows the transformation of such steels with a suitable ductility / strength behavior. By the higher Strength can In addition, components with the same stability - and thus safety - with less Material to be made. The increased deformability allowed about that In addition, an easier production of complex shaped components, such as for example, of carrier structures.

One central concern of the automobile industry is the reduction of the Fuel consumption over the Reduction of vehicle weight with unchanged safety, in particular Crash safety, - by The construction of lighter vehicles can succeed. savings offer higher strength steels, because of the increased Strength less material used with the same dimensional stability can be.

By the roll forming process according to the invention with integrated forming can high strength steels be deformed. The forming of the steels is economical according to the invention configured in which all process steps take place on a plant can. This reduces the production times of the components.

One Another object of the present invention relates to a roll forming for profiling of metal-containing components with at least one integrated device for forming, this device suitable is to change the roll profile cross-section, in particular locally.

One Advantage of the roll forming system according to the invention is that all process steps on a single plant feasible are causing it to increase the output (product increase) and save time can. A high output per time results in a high efficiency the roll forming machine according to the invention, wherein the Walzprofilieranlage is designed conventionally or can be configured as a flexible Rollprofilieranlage. In the usual Rollforming but the economy is limited by the high set-up and adjustment of the tool sets. This applies in particular special for small lot sizes. The Cause for the high set-up and Einstellaufwand is justified in the conventional system engineering, the when switching to the production of another profile usually makes a tool change in all scaffolding required and cause high setup times, which in turn increase the productivity of the process adversely affect.

Of the The invention provides the significant advantage that components with strongly divergent cross-sectional changes in a single Roll forming machine with an integrated forming device locally can be transformed. there deleted the transport of the roll-profiled components to a separate forming line. The well-known logistics problem with conventional roll forming is connected, deleted according to this invention.

One Another advantage of Walzprofilieranlage invention Comparison in particular to a bending device for profile bending elongated components is that by means of the roll forming according to the invention with an integrated forming device rolled sections with complex Profile cross sections are roll profiled, such. B. rolled sections with rejuvenations or rolled profiles in which, for example, the complete component flank shifts, wherein the angle of the component edge is maintained. this makes possible the integrated production of very stable structural and safety components.

In an advantageous embodiment of the roll forming is the integrated device for forming parallel to the transport direction designed to be profiled component displaced.

An advantage of this embodiment is the application of complex cross-sectional variations in designated component areas, wherein the components may have different component lengths. In this case, the roll forming system according to the invention can be controlled in such a way that the component region to be changed in cross section is deformable in the shaping device, preferably in a deep drawing device. To carry out the forming process can, the Walzprofilieranlage is preferably stopped for one to two seconds, while the component is formed and then takes place the further roll forming instead. In this case, the integration of the forming device in the roll forming installation proves to be advantageous, wherein the roll forming operation in the roll forming installation is conventionally to be carried out or else can be carried out as a flexible roll profiling operation.

Further can the forming device so in the transport direction of the profiled Be moved component that on the same roll profile several times Changes in cross section can be introduced. Furthermore, the distance of the cross-sectional changes be designed to be variable to each other such that components are the same Length in have different component areas cross-sectional changes. The displaceable embodiment of the device for forming enabled by the flexibility the plant a cost-effective Manufacturing, which makes the system economical.

The Forming device can also be spatially separated from a first Be arranged part of the roll forming, so that first a roll forming process is carried out and subsequently separated the forming process takes place, followed by in a further part of the roll forming the final Walzprofilierprozess expires.

Furthermore allows the roll forming according to the invention a production of modular components with different rolled profile cross sections on a roll forming line without the use of an extra Tool. Only through the use of the production step roll forming can Components are manufactured modular. Thus, similar components which are for example, only in length differ without setup procedures and separate tool sets by appropriate cutting produced at the end of the roll forming. In addition, the leads Modular manufacturing to reduce manufacturing costs and to one opposite a production with a conventional thermoforming system increased efficiency.

It is possible, too, to connect the forming device rigidly with the roll forming.

alternative to this embodiment Is it possible the integrated forming device in the roll forming transverse displaceable to the transport direction of the component to be profiled embody.

hereby is guaranteed that by means of the inventive system in particular components that do not have mirror-symmetrical geometries in relation to the longitudinal axis have, can be produced.

Furthermore this embodiment is particular for integrated Forming devices with smaller forming tools appropriate.

In an advantageous embodiment The roll forming system is alternatively or additively the integrated Device for forming laterally in the plane of the horizontal in a vertical angle relative to the transport direction of the to be profiled component mounted in parallel sliding.

These Arrangement offers the advantage that lateral impressions with complex geometries are introduced into the roll profile. Thus are lateral cross-sectional changes represented in rolled sections, by means of conventionally arranged deep-drawing devices can not be produced.

Further allows the roll forming according to the invention the modular production of components with complex rolled section cross sections on a roll forming line without the use of an extra Tool.

In an advantageous embodiment the Walzprofilieranlage with integrated forming device is it be controlled so that a discontinuous operation is possible.

One essential advantage of the roll forming according to the invention is discontinuous operation, with elongated roll-profiled components Changes in cross section in different component areas during profiling without one Plant change can be introduced. These are the times the control in dependence from the desired component changes varied and freely selectable embody.

A further advantageous embodiment of the Walzprofilieranlage invention refers to that the device for forming a device for beading and / or a device for tensile and / or pressure forming, in particular thermoforming.

One Advantage of a roll forming machine with one or more integrated Crimping devices is that stiffening beads with the device can be introduced only in the areas of the rolled section, in which a high rigidity is required.

It is particularly advantageous in this case that by means of the device for deep drawing in the rolled sections complex profile cross sections are introduced such that after deep drawing the complete component flank shifts, whereby the angle of the component flank can be maintained.

In a further embodiment the roll forming machine has the integrated device for forming a punch and a hold-down, and in particular an inner punch on.

In special size has the roll forming according to the invention proven with at least one integrated thermoforming device that despite the deep-drawing process in the steel material, a material flow, the characteristic of high Forming degrees during of thermoforming is observed only to a lesser extent in the component is.

One Advantage of the thermoforming device is the design of the stamp, the multi-part design is such that the stamp parts are mutually displaceable. This gives impressions with variable geometries in the roll profile can be introduced. This embodiment of the stamp proves to be particularly economical because by it the set-up times at Tool change eliminated. Thus, the output of the plant elevated. During deep drawing, the stamp is lowered and by a Downholder, which prevents wrinkling, generated in the Roll profile the desired Cross-section, wherein the rolled section is positioned on an inner punch. The inner punch has the negative shape of the desired Profile profile cross-section on.

Hereinafter, the objects according to the invention based on embodiments and the 1 and 2 explained in more detail. Here are from the figures and their description further features essential to the invention and advantages of the invention. Showing:

1 Schematic representation of Walzprofilierprozesses invention

2 Schematic representation of a thermoforming device

The 1 schematically shows an exemplary embodiment of the roll forming process according to the invention for roll profiling 4 and 6 a starting material. The starting material is TRIP steels as a coil 1 used. The TRIP steels are very strong with increased ductility and by the method according to the invention these are readily deformable.

In a first process step, the starting material is directed 2 , then marked in a second 3 , Subsequently, in a third process step 4 the starting material in the first part of the roll forming plant 17 roll formed. This is a uniform, over its length constant roll profile 14 , such as a U-profile, generated. After the third process step 4 becomes the roll forming machine 17 preferably stopped for one to two seconds to the rolled section 14 locally reshape, in which in a thermoforming device 16 the rolled section 14 is deformed. In this process step is by means of deep drawing 5 the rolled section 14 cold formed so that it has local changes in cross section.

The thermoforming device 16 in 2 includes a stamp 11 , a hold-down 12 and an inner stamp 13 , This is the thermoforming device 16 preferably parallel in the roll forming 17 along the transport direction 15 movably arranged. The thermoforming device 16 is doing in the transport direction 15 of the component to be profiled so shifted that on the same roll profile 14 with the one deep drawing device 16 multiple changes in the cross section can be introduced.

In a next step, the further roll forming takes place 6 instead of. After that is punched 7 and then cropped 8th , When pruning 8th Bumps in the component are removed. In a next step, a joining takes place 9 instead of. For example, spot welds are possible on the lower surface of the component.

In a final process step 10 is cut to length. The component is cut to the desired length.

It It should also be noted that the invention is not limited to the previously described embodiment limited is, but rather transferable to other Walzprofilieranlagen is.

For example, it is conceivable to cut to length the method step described in the exemplary embodiment 10 immediately after the process step trimming 8th perform.

It would also be for the production of support structures another starting material conceivable. For example, instead of the proposed TRIP steels, TWIP steels, which are highly deformable at elevated strength, or BTR steels, or other thin, but very hard sheet metal alloys, such as Usibor steel, or BOR steel, or BORON steel or for example ZSTE steel or for example, stainless steels, such as chromium or manganese alloyed stainless steels become.

An essential advantage of the erfindungsge The method is to reduce the non-productive time, for example, the setup times. In doing so, the restart times of the system, in particular during deep-drawing operations, are shortened.

1

coil

2

judge

3

To mark

4

roll Forming

5

thermoforming

6

roll Forming

7

punch holes

8th

trimming

9

Put

10

Shorten

11

stamp

12

Stripper plate

13

inside the temple

14

rolled section

15

transport direction

16

Deep-drawing device

17

roll forming

Claims (11)

Process for the production of metal-containing components, in particular of vehicle support structures, in which a metal-containing starting material of a roll forming installation ( 17 ) and to a rolled profile ( 14 ) is roll-profiled, wherein during the roll forming takes place a forming, characterized in that by means of the forming of the rolled section cross-section is changed. Process for the production of metal-containing components according to claim 1, characterized in that the process steps roll forming ( 4 ), Reshaping ( 5 ) and roll forming ( 6 ) are passed through one after the other. Process for the production of metal-containing components according to claim 1 or 2, characterized in that the roll forming system ( 17 ) is driven in discontinuous operation. Method for producing metal-containing components according to one of Claims 1, 2 or 3, characterized in that the rolled section ( 14 ) is cold formed to change the cross section. Method for producing metal-containing components according to claim 4, characterized in that during forming ( 5 ) and / or to train and / or pressure, in particular deep-drawn and / or stretch-drawn, is formed. Process for the production of metal-containing components according to one of the preceding claims, characterized that is reshaped locally. Process for the production of metal-containing components according to one of the preceding claims, characterized that as a starting material higher strength steels and / or deep drawing steels and / or Ti alloys and / or Ni alloys and / or lightweight steels and / or metal-containing composite materials are used. Roll forming machine ( 17 ) for profiling metal-containing components with at least one integrated device for forming, characterized in that the integrated device for forming ( 16 ) is adapted to change the roll profile cross-section, in particular locally. Roll forming machine ( 17 ) according to claim 8, characterized in that the integrated device for forming ( 16 ) parallel to the transport direction ( 15 ) of the component to be profiled is designed to be displaceable. Roll forming machine ( 17 ) according to claim 8 or 9, characterized in that the device for forming ( 16 ) represents a device for beading and / or a device for tensile and / or pressure forming, in particular deep-drawing and / or stretch-forming. Roll forming machine ( 17 ) according to one of the preceding claims 8 to 10, characterized in that the integrated device for forming ( 16 ): - a stamp ( 11 ) and - a hold-down ( 12 ), and in particular - an inner punch ( 13 ).